Apparatus for making variegated hard surface covering



A. `c. PERRY 2,374,496

PPARATUS FOR MAKING. VARIEGATED HARD SURFACE COVERING April 24, 1945.

OriginalvFned oct. 3, 1940 2 sheetsheet 1 April 24, 1945.

A. c. PERRY 2,374,496

AARATUS FOR MAKING VARIEGATED HARD SURF-ACE COVERING 2 Sheets-Sheet 2 originl Filed Oct. s, 1940 L i l I the Patented Apr. Z4, 1945 APPARATUS ron MAKING VARIEGAT'ED ,d

HAItn SURFACE oovEmNG `Arlington C." Perry, Lancaster,

Pa., assigner to Armstrong" Cork Company, Lancaster, TIa., a corporation of Pennsylvania `Original application October 3, E1940, Serial No.`

359,506. Divided and this application January 14, 1943, Serial N0. 472,364

`4 claims. (Crispi-2) p o This-application is a division of my copending application, Serial No. 359,506, ledOctober 3,

1940, and relates to an apparatus for making variegated linoleum by what is generally termed cross-rolling process.

The cross-rolling process of` making variegated linoleum as applied to the continuous production of` linoleum on rotary inlaying machines 0f the Walton or Batten type contemplates the formation of a sheet having a definite directional grain: ing commonly called jaspe, rality of such sheets and passing the overlapped sheets through a sheeting calender at right angles to the direction of graining thus forming an integral sheet and shortening and spreading the jaspe graining of the face of the sheet to obtain the desiredjvariegation which is generally `considered to resemble marble. It is known that graining produced by this process varies throughout the thickness ofthe sheet and that thegraining of the back of the sheet bears only a remote resemblance to the graining on the face of the sheet.

One of the chief problems present in such practice residesin the visible discontinuity between sheets where an overlappedor overlapping sheet adheres to and becomes an integral portion of a following orpreceding sheet. This phenomenon is termed "hook-on in the industry and appears to be a visible distortion of -face graining which is not compatible with the required variegation and presents an entirelydifferent appearance at the sections where the overlapped `sheets `join one another. The cause of hook-on is. not known with any degree of certainty but it is believed to `be due almost entirely to the abrupt change in volume of material present in the nip of the rolls at the overlapped portions of the sheet and the subsequent flow and surge of the plastic material resulting from increased pressure. It may be due` in part to the fact; that in some cases the edge p portions of the overlapped vsheets presented to the calender rolls turn over slightly when subjected to pressure and thus permit back graining to appear on the face of the sheet. In anyevent, this visible discontinuity is a serious distortion-of .face grainng which is undesirable and which `annually creates an enormous waste in the production of variegated'linoleuml on rotary inlaying machines.

The chief object of my invention is to provide improvements in apparatus for making variegated hard surface covering by the cross-rolling process designed to eliminate substantially or entirely the visible discontinuity present in those portions overlapping a pluof the Iinished sheet where overlapped sections join. Anobject of my invention is to provide an apparatus for producing variegated linoleum which is economical in operation and highly satisfactory in service. A further object is to obviate the abrupt change in Vvolume of plastic composition atthose places where onesheet joins and adheres to a second sheet in the manufacture `of variegated hard surface covering.

This invention relates yto a device for making variegated hard surface covering comprising, in combination, a sheeting calender adapted toform a sheet having a denite directional grainng, a

`perforating element adapted to forma plurality of openings in the sheet, means 'for tearing the sheetalong the openings so as to `form two sections each of which has an irregularedge composed of torn and formed portions,`and 'means for cross-rolling a plurality of sections disposed in` overlapping relationship withfthe irregular edge of one section adjacent the face of a second sheet to form a `continuous sheet.

The attached drawings illustrate a preferred embodiment of my invention, in which 1 Figure 1 is a plan view of my device for making variegated hardv surface covering by the crossrolling process;

Figure 2 is a view partly in elevationand partly insection `of a portionof` the device shown in Figure l, the frame of the device being removed to illustrate the skiving and perforating mechanism;

` Figure 3 is a View in elevation 'of a suitable skiving tool; t l Figure 4 is an isometric viewof the perforating cutter;

Figure 5 is a sectional view of a sheet of linoleum composition serving to illustrate the skived recess formed in its under surface;` and 'Figure 6 is an exaggerated plan view of a portion of asheet provided with arcuate slots..

`Suitable `mixing equipment is provided for forming two dilerently colored linoleum compositions. f It will be appreciated suitable equipment may be provided for any desired number of differently colored compositions. The differently colored compositions are blended into a'eohesive vari-colored mass which is fed'toa two-roll sheeting calender 2, `as shownwin `liigure l. The face` roll` 3 of the calender `IZ is maintained at a lower temperature than `the back roll'd in order to sheet. A doctor blade (not shown) is usually provided toremove the jaspe sheet from the roll yii. Such equipment is well-known in the industry and does not require lengthy description for a full and complete understanding of my apparatus and method. v

It is desirable that the edge of the sheet which is disposed adjacent the face of the subsequent.or

preceding sheet be irregular in contour and have some portions thereof extending beyondA the body of the sheet to a greater extent than..

other portions since this materially reduces lthe volume of plastic composition present inthe nip of the cross-rolling calender when overlapped sheets are joined and made into an integral sheet. I have found that an irregular edge formed-by perforating and tearing the edge substantially alternately achieves the .desired result. '.[iprovide a perforating tool or cutter having a plurality .of oppositely .curved teeth' whichare bent outwardlyin opposite directions. lThe cutter 6 is thus adapted `to form a plurality 4oi offset arcuate slots 'l in a formed sheet 8. It will be understood. of course. the .teeth of the neriorating tool 5 may be straightor curved in the same direction if desired. v

Preieralblv. the tool v5i is disposed 'adjacent the roll V3 in order that such roll may serve as a platen therefor and is supported by a lever 9 p-ivoted on a shaft/ID extending across the device. The lower portion II of the lever 9 engages and isheld in nontact .with a pinlZ held in a support I3. As the ninr i2 is moved outwardly, it rotates the lever 9 about the shaft IIJ to move the perforating tool 5 upwardly toward the roll 3. As the .pin I2 is retracted within the support I3, the weight of the oer-forating tool 5 i: sufficient to rotate the lever Sfabout the shaft lll thus moving the tool 5 in the opposite direction. The tool 5 is adjustable laterally of the shaft AIll in order' that the slots 'I may be formed in any desired positionlaterally of thesheet 8.

"The sheet 8 containing perforations, slots or openings 1 is then led over a bar 1I4 as shown in Figure l. which serves to tear the sheet into two similar sections 8a and 8by by connecting the o# set openings; Thus similar sections are producedv of alternately torn and formed portions. The v sections ,are placed on a conveyor I5 which carries them to a table I6 positioned adjacent the rolls ofa crossrolling lcalender Il. Such sections 8a and 8b while traveling on the conveyor are subdivided, either manually or mechanically, into sui-table sizes to be fed to the cross-rollingA calender Il.

The subdivided sheetsare disposed in overlapping relation on the table I6 with the irregular edge of one sheet disposed adjacent the- Iface or the other sheet. As shown in Figure l. the subdivided sheets are fed to the cross-rolling calender V! vface-down and. accordingly, the irregular edge of the sheet is the rear edge. Oli course. ifacontinuous sheet I8 were to be formed face-upQ-the irregular edge would be that edge of ythe sheet first fed to the cross-rolling calender. The overlapped sheets are fed to the rolls of the cross-rolling calender I1 vat right angles tothe direction of grainihg to forma continuous integral sheet I8 and to further shorten and spread Jrhe graining to form variegations on the face thereof which resemble marble.

2,374,496 1f Li I have found it of material aid in the substantial elimination of hook-on to provide the irregular edge of the sheet with a tapered portion of less thickness than the body of the sheet.y This, of course, materially reduces the volume of plastic. composition present inthe nip of the cross-rolling calender at vthose points where overlapped sheets adjoin. In the copendng applica- :tion of Virgil Spencer, Serial No. 359,328,'f`1led OctoberZ, 1 940, there is shown a skiving device .especially suitable for this purpose. As shown in Figur-e 2, there is provided a skiving tool I9 v whichy serves to skive or form a recess or groove 20 in the formed jaspe Sheet 8. The skiving tooll preferably is disposed adjacent the roll 3 in orde-r that the roll 3 may serve as a platen therefor., but it will be understood the tool i 9 may be used to skive a groove 2l! in the sheet 8 after ,it has been removed from the roll 3. `In

such case, a suitable backing plate or platen need beiprovided.- The ,Skivng tool .I9 skivesnathin tapered ribbon from the sheet 8 thus leaving a tapered groove or recess therein. i

The skiving tool I9 preferably consists ofathin metal strip 2l having -a :sharpened and tapered edge; Z'Zf-bent yinto the lorin shown in Figure 3. ThevJ-tool ISis vbolted to a metal Ibar or rod 2.3 heldin 2a barrel 124il adjustably vmounted upon a-sliaft 25.'.extending across'the device. The skiv ing-tool I9 is adj-usted by means loi 'a' hand'wheel 26 secu-rednto va threaded rod 2l which ,extends through the barrel -24 and into athreaded opening-28 provided inthe bar V23. The L'bar 23 is keyedto .the barrelato-prevent its'frota'tion. Rotation of the hand-Wheel .26 causes rotation of the lthreaded rod 2l permitting the `bar 23 to be raised and lowered in the barrel Zitto move the skiving tool I9'toward and from the ro-ll 3, thus varying .the depth of the .groove or .recess .ski-ved in the formed sheet.

-f In operation, .a cohesive var'i-colored'mass of linoleum .composition is fed to the two-roll 4calender 2 and formed into a sheet 8 having a denite directional graining.v kWhile the sheetadheres tothe cold roll :3,the skiving .tool 119 skives a portion of ythe under .surface of such vsheet so :as vto reduce its thickness, preferably at its 'central portion. UThe-perforating .tool 5 then, Vwhile the sheet still adheres to the coldl rofll`3, forms a 'plurality of slots FI vin the skived 1portion'ii offfthe sheet 8. The sheet is doctored from the-cold roll 3 and passed over a ybar I4 which tears it in `tw-o separate sections ay" and 8b by connecting the' offset slots l. Each section so `formed lpossessesI a tapered irregular edge formed of alternate torn and formed portions.` TheA sections :8a .and 81h are placed'upojn a conveyor I5 which :carries them to the cross-rolling calender- Il. During their passage .on the conveyor f1.5, `the sections' are subdivided,manually Vor mechanically, into sheets fof suitable size "for feeding to the cross-rolling calender. i f- The sheets are placed in overlapping relationship on the table I=6 with -the'tapered irregular edge of one sheet disposed adjacent the face of lar `edge is the rearward edge orthe sheet. The

sheets are cross-rolled to spread and shorteh'zthe' graining and to form .a continuous integral sheet which may be placed upon a suitable backing or' fed-to the ydies .of the rotary inlayng machine .as welleknownin theindustry. I

l The practicey outlined above substantially or bel entirely eliminates the visible discontinuity tween overlapped sheets. `Distortion of face graining at the overlapped edgesdoes not occur to any substantial extent and accordingly, a continuous variegated linoleum sheet is` produced in which the graining presents substantially the desired appearance over the face of the sheet. The enormous waste created by hook-on is entirely eliminated and a more desirable and decorative sheet is produced. The improvements in the ycross-rolling process above described add little or nothing to the costsinvolved in making the sheet. The additional apparatus required in order to eiectuatesuch improvementsis inexpensive and does not require frequent replacement. Needlessto say, however, the chief advantage of my improved process resides in the substantial or entire elimination of `grain distortion at those sections of the continuous sheet where overlapped sheets are adhered to one another.

While I have described and illustrated a prel ferred embodiment of my invention, it will be un-` i derstood my invention isnot so limited since it may be otherwise embodied or practiced within .the scope of the following claims.

I claim:

1. In combination with a sheeting calender, a skiving tool adapted to form a recess extending longitudinally of the under surface of a sheet of hard surface covering material, means to adjust said tool to vary the depth of the recess, and a perforating element for forming a plurality of openings in the recessed portion of the sheet, said sheet being adapted to be torn along the openings so as to form two sections each of which has an irregular edge formed of alternate torn Vand formed portions and of less thickness than the body of the section. i

t 2. In combination with a sheeting calender, a skiving tool adapted to form a `recess extending longitudinally of the under surface of a sheet of hard surface covering material, means to adjust said tool to vary the depth of the recess, and a Y circular cutter adapted to forma plurality of offset openings in the recessed portion of the sheet, said cutter having a plurality of alternately outwardly and inwardly bent` cutting portions disposed in spaced relationship to one another, said sheet being adapted to be torn along the offset openings to form two sections each of which has an irregular tapered edge having at least a, portion thereof formed of alternate torn and formed portions.

3. In a device for making a variegated sheet of hard surface covering, the combination of a sheeting calender adapted to form a sheet having a definite directional graining, a ski-ving tool disposed adjacent thereto adapted to form a recess extending longitudinally of the under surface of a formed sheet, means to adjust said tool to vary the depth of the recess, and a perforating element adapted to form a plurality of openings in the recessed portion of the sheet, said sheet being adapted to be torn along the openings so as to form two sections each of which has an irregular edge of less thickness than the body of the section.

4. In a device for making `a variegated sheet of hard surface covering, the combination of a sheeting calender adapted to form a sheet havi ing a denite directional graining longitudinally thereof, and a perforating member disposed adjacent said calender Afor `forming a, plurality of openings longitudinally of said sheet, said perforating member comprising a circular cutter having a plurality of alternately outwardly and inwardly bent cutting portions disposed in spaced `relationship to one another, said sheet being adapted to be torn along the openings so as to ,form two sections each of` which has an irregular edge composed of torn and formed portions.

ARLINGTON C. PERRY'. 

